Eberspaecher Introduces 800-Volt Heating Solutions for Next-Generation Electric Vehicles
New coolant and air heaters deliver efficient thermal management for extended EV range, faster charging, and enhanced comfort across 400V and 800V platforms.
www.eberspaecher.com
The biggest challenges facing electromobility include battery range requirements, charging times, and comfort. Optimized thermal management plays an important role here, especially through the use of electrical high-voltage technologies. With two new solutions for 800-volt electrical systems, Eberspaecher is expanding its portfolio to include coolant and air heaters.
The growing number of battery-powered electric vehicles is key to achieving climate-friendly mobility. Widespread acceptance is still influenced by technological challenges, such as range, driving comfort, and charging times. Advanced thermal management systems are required to overcome these challenges and improve efficiency, comfort, and system stability equally. Eberspaecher is an experienced system developer and supplier to the automotive industry. For many years, it has manufactured key components for temperature control in battery electric vehicles, including high-voltage electrical heaters. They provide fast and reliable temperature control, especially in cold conditions. This is precisely where heat pump systems often encounter performance limitations. Eberspächer offers two new solutions for 800-volt vehicle electric systems: a coolant heater with thick film technology and a air heater with PTC technology. These solutions provide targeted, demand-based heat output for the passenger cabin and battery conditioning. Both systems can be integrated into OEM systems on a modular basis.
Coolant heater: High-performance, compact, and safe
Eberspaecher offers a compact and powerful alternative to classic PTC technology with its coolant heater based on thick film technology. The core component is a thick film element (TFE), which is applied to a metal plate via a screen-printing process. This design provides high heat output in minimal installation space. The component conditions the vehicle battery and achieves up to 12 kW of output at 800-volt – a key contribution to extending battery life and reducing charging times. A further advantage is the flexibility of the voltage: Although many BEV platforms rely on an 800-volt architecture, they must also be compatible with the 400-volt charging infrastructure, as this currently accounts for the majority of the global charging network. The coolant heater has been designed specifically for this scenario, delivering sufficient output even at 400-volt. The safety concept is based on multiple sensors and an independently operating second shutdown path, ensuring maximum operational safety. This reliably monitors and controls thermal processes. The thick film heater is suitable for both passenger cars and trucks, and it has already been selected by several automobile manufacturers for use in their series lines. Production is scheduled to begin in 2027.
A compact solution for battery conditioning is provided by the coolant heater based on thick film technology.
Air heater with multi-zone function: Comfort and performance for the cabin
The air heater, which is installed directly in the air-conditioning system, supplements the portfolio. The multi-zone function enables the driver to control the temperature separately in up to four zones in the interior. For example, the driver can set different temperatures for the driver and front passenger sides. PTC technology is used for the air heaters, which are located close to the passenger and partly within the firewall. Due to the system’s inherent self-regulating effect, reliable protection against overheating is guaranteed With a power range of 3-8 kW, the heater has been designed to accommodate both 400- and 800-volt architectures. Eberspaecher avoids using adhesives in the setup of heating elements wherever possible, thereby minimizing the risk of unwanted emissions in the passenger compartment. The product will be available in Asia, Europe, and North America starting in 2028.
www.eberspaecher.com
